Auger-impeller bucket assembly for a snow removal device

ABSTRACT

A snow removal device includes a frame, an engine supported at least in part by the frame, a mobility assembly and a bucket assembly. The mobility assembly is operably coupled to the frame and the engine to provide mobility of the snow removal device responsive at least in part to operation of the engine. The bucket assembly is operably coupled to the frame and houses a material conveyor and an impeller, each of which operate via power from the engine to provide snow removal operations. The bucket assembly includes one of each of a first stage housing, an impeller housing, and a discharge chute base. The bucket assembly is formed such that at least two among the first stage housing, the impeller housing, or the discharge chute base are integrally molded or cast as a single unitary component.

TECHNICAL FIELD

Example embodiments generally relate to outdoor power equipment and, more particularly, relate to a structural housing, or bucket assembly, for an auger/impeller of a snow removal device.

BACKGROUND

Grounds care/yard maintenance and other outdoor tasks associated with grooming and maintaining property are commonly performed using various tools and/or machines that are configured for the performance of corresponding specific tasks. Certain tasks, like snow removal, are typically performed by snow removal equipment such as snow blowers or snow throwers. The snow removal equipment may, in some cases, be walk-behind models. However, snow blower or snow thrower attachments can sometimes be added to lawn tractors or other riding yard maintenance vehicles as well.

Walk behind snow blowers or snow throwers may be single stage or dual stage snow removal devices. A single stage snow thrower may include a high speed auger blade that is rotated at the front of the snow thrower. The rotation of the auger blade may intake snow and impart momentum on the snow to eject the snow through a chute all in one stage of operation. A dual stage snow blower may add an additional stage by having the auger blade (e.g., the first stage) feed snow into an impeller (e.g., the second stage) that imparts momentum on the snow to eject the snow through a chute. In such an example, the first stage auger may operate at lower speeds since the impeller will provide a momentum boost for snow ejection.

Dual stage snow blowers have additional components, and therefore may add additional complexity and cost to the design and manufacture of certain aspects of such devices.

BRIEF SUMMARY OF SOME EXAMPLES

Some example embodiments may therefore provide alternatives for employment in manufacturing processes that may reduce the number of separate parts that need to be joined together during production of a dual stage snow blower. In this regard, for example, some example embodiments may provide an auger-impeller bucket assembly that includes an auger housing, an impeller housing, and a discharge chute base. However, rather than separately manufacturing such components and joining them together, example embodiments may integrally form at least two of such components (e.g., the auger housing, the impeller housing and the discharge chute base) together in a single unitary piece of cast or molded material. In some cases, all three components may be formed from a single cast or molded material into one unitary bucket assembly that lacks any discernable joints between at least some of the components thereof. Thus, no additional manufacturing or assembly steps, and no joining materials (e.g., welds, bolts, snap fittings, dovetail joints, rivets, or other joints) may be needed in relation to the formation or processing of at least two of the bucket assembly components. Accordingly, overall assembly and/or production of the snow removal device on which the bucket assembly is employed may be accomplished with lower cost and/or complexity.

In one example embodiment, a snow removal device is provided. The snow removal device includes a frame, an engine supported at least in part by the frame, a mobility assembly and a bucket assembly. The mobility assembly is operably coupled to the frame and the engine to provide mobility of the snow removal device responsive at least in part to operation of the engine. The bucket assembly is operably coupled to the frame and houses a first stage material conveyor and an impeller, each of which operate via power from the engine to provide snow removal operations. The bucket assembly includes one of each of a first stage housing, an impeller housing, and a discharge chute base. The bucket assembly is formed such that at least two among the first stage housing, the impeller housing, or the discharge chute base are integrally molded or cast as a single unitary component.

In another example embodiment, a bucket assembly for a snow removal device is provided. The bucket assembly includes a discharge chute base, an impeller housing and a first stage housing. The discharge chute base is in communication with a discharge chute to direct snow ejected from the snow removal device. The impeller housing is adjacent to the discharge chute. The first stage housing is adjacent to the impeller housing. The bucket assembly is formed such that at least two of the first stage housing, the impeller housing, or the discharge chute base are integrally molded or cast as a single unitary component.

Sonic example embodiments may decrease the cost and complexity of assembly of a dual stage snow removal device and may also, in some cases, improve the structural integrity of the bucket assembly.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which arc not necessarily drawn to scale, and wherein:

FIG. 1 illustrates a perspective view of a dual stage snow removal device according to an example embodiment;

FIG. 2 illustrates a perspective view of a bucket assembly of a snow removal device according to an example embodiment; and

FIG. 3 illustrates an exploded perspective view of a bucket assembly of a snow removal device according to an example embodiment.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout. Furthermore, as used herein, the term “or” is to be interpreted as a logical operator that results in true whenever one or more of its operands are true. As used herein, operable coupling should be understood to relate to direct or indirect connection that, in either case, enables functional interconnection of components that are operably coupled to each other.

In a dual stage snow blower, the auger and impeller are typically housed proximate to each other to enable the snow to be easily passed from one stage to the next. However, the auger and impeller may have different orientations and/or axes or rotation. Thus, portions of the bucket assembly in which the auger and impeller are respectively housed may be somewhat discontinuous. As such, two separate housings (e.g., an auger housing and an impeller housing) are typically joined together into a single housing assembly. Similarly, the discharge chute base often forms yet another discontinuous and separate component that needs to be joined to the impeller housing. The sidewalls of the auger housing may form yet another separate component needing to be joined with other components.

The joints between all of these components may be formed in a number of ways. In some cases, the joints could be formed by welding. However, in other cases, bolts, rivets, snap fittings, dovetail joints, or other joining mechanisms may be employed. In all of these examples, some form of assembly is required, and thus there may be additional labor cost. Dependent upon the joining mechanism, there may also be additional material cost or complexity in manufacturing processes. Moreover, the requirement to employ joining mechanisms further adds to labor costs for additional assembly steps.

Some example embodiments may reduce the cost and complexity of manufacturing a dual stage snow removal device by providing an auger-impeller bucket assembly that includes an auger housing, an impeller housing, and a discharge chute base. However, example embodiments may integrally form at least two of the components of the bucket assembly (e.g., the auger housing, the impeller housing and the discharge chute base) together in a single casted or molded material. Accordingly, joining together separately manufactured components may be avoided. Example embodiments may therefore provide for employment of a casted or molded material into one unitary bucket assembly that lacks any discernable joints between at least two of the components thereof. Additional manufacturing or assembly steps, and joining materials (e.g., welds, bolts, snap fittings, dovetail joints, rivets, or other joints) may therefore be avoided or at least reduced.

FIG. 1 illustrates an example of a dual stage snow removal device 10. Although the snow removal device 10 of FIG. 1 is shown as a walk-behind device, it should be appreciated that the working portion of the snow removal device 10 could also be utilized in connection with ride-on devices (e.g., as an attachment to the front of a lawn tractor or other ride-on vehicle. Thus, example embodiments are not limited to application on walk-behind devices, In some embodiments, the snow removal device 10 may include a chassis or frame 15 to which various components of the snow removal device 10 may be attached. For example, the frame 15 may support an engine 20, such as a gasoline powered engine, and a working assembly 30. Operation of the engine 20 may be initiated by a recoil starter via pulling of a recoil starter handle by the operator. However, in other embodiments, the engine 20 may alternatively be started via a key, switch or other similar device.

The snow removal device 10 may include wheels 40 or continuous tracks forming a mobility assembly on which a substantial portion of the weight of the snow removal device 10 may rest, when the snow removal device 10 is stationary. The mobility assembly (e.g., the wheels 40 or continuous tracks) may also provide for mobility of the snow removal device 10. In some cases, the mobility assembly may be driven via power from the engine 20. However, in other cases, the mobility assembly may simply provide for mobility of the snow removal device 10 responsive to pushing by the operator. In other words, for example, the mobility assembly may be an active or passive provider of mobility for the snow removal device 10.

In this example, the working assembly 30 includes a rotatable auger 32 (or auger blade) that is configured to work (e.g., spin, rotate, turn, and/or the like) in order to direct snow toward an impeller 34 (or impeller blade) that also works (e.g., spins, rotates, turns, and/or the like) to direct snow toward a discharge path to be ejected from the snow removal device 10. However, it should be appreciated that the working assembly 30 of some embodiments could include a power brush or other implement used to move snow toward a second stage device (e.g., the impeller 34) for ejection from the working assembly 30. Thus, as used herein, the term “first stage material conveyor” should be understood to encompass both an auger or a power brush, and the term “first stage housing” should be understood to cover both an auger housing or a power brush housing that house a first stage material conveyor of the working assembly 30 of a dual stage snow removal device. In an example embodiment, the working assembly 30 may be powered via operable coupling to the engine 20. The operable coupling of the working assembly 30 to the engine 20 may be selectively engaged and/or disengaged (e.g., via a clutch, one or more selectively engageable chains/belts/pulleys, a friction wheel or other similar devices). Components of the working assembly 30 (e.g., the auger 32 and the impeller 34) may be housed in a bucket assembly 100 as described in greater detail below.

As can be appreciated from FIG. 1, the auger 32 may rotate about a first axis that is substantially parallel to the surface on which the snow removal device 10 operates. The first axis may also be substantially parallel to an axle extending between the wheels 40 of the snow removal device 10. In other words, the first axis may extend from one side of the snow removal device 10 to the other side of the snow removal device 10 within the bucket assembly 100. Meanwhile, the impeller 34 may rotate about a second axis that is substantially perpendicular to the first axis. Although the second axis could also be parallel to the surface on which the snow removal device 10 operates, in some embodiments, the second axis may be angled upwardly away from the surface and toward a discharge chute 50 of the snow removal device 10 in line with a portion of the ejection path. During the operation of the auger 32 and the impeller 34, the bucket assembly 100 prevents escape of snow and directs the snow into the ejection path. Thus, the bucket assembly 100 protects the operator from blowback and also allows for a somewhat orderly disposal of the snow that is ejected by the snow removal device 10.

The ejection path of the snow removal device 10 may be formed at least in part by the bucket assembly 100 and the discharge chute 50. As such, for example, the ejection path may begin proximate to an input of the impeller 34, at which point snow is imparted with momentum at an output of the impeller 34 to be pushed toward the discharge chute 50. The discharge chute 50 may include a chute body 52 and a chute deflector 54. The chute body 52 may be rotated in order to enable an operator to select which direction to discharge snow pushed through the ejection path. The chute deflector 54 may be adjusted up and down by the operator to control the height of the discharge stream of snow that is ejected via the discharge chute 50. In an example embodiment, the discharge chute 50 (and specifically the chute deflector 54) may be the last component in the ejection path through which snow may travel responsive to rotation of the auger 32 and the impeller 34.

In an example embodiment, the snow removal device 10 may further include a control panel 60, which may include ignition controls, operating levers 62 and/or other controls or informational gauges. The control panel 60 may be provided to be accessible from the rear of the snow removal device 10 by an operator standing or walking behind the snow removal device 10 (e.g., at an operator's station) and capable of pushing, steering or otherwise controlling movement of the snow removal device 10 using a handlebar assembly 70 or some other steering assembly. In some examples, the handlebar assembly 70 may include at least two arms 72 that may extend up and rearward away from the side panels 22 to provide a structure for an operator to hold to facilitate direction and operation of the snow removal device 10. The arms 72 may extend substantially parallel to each other and may be positioned to extend at an angle of between about 30 degrees to 90 degrees from the horizontal back toward an operator standing or walking behind the snow removal device IO at the operator's station.

The bucket assembly 100, which is shown in greater detail in FIG. 2, and an exploded view of which is shown in FIG. 3, may house the auger 32 and the impeller 34. It should be appreciated that the components shown in the exploded view in FIG. 3 represent components that are typically manufactured separately and assembled with some form of joining technique used to combine the components into an assembly (as shown in FIG. 2). This is typically done because of the discontinuous nature of each of these components relative to one another in a final bucket assembly. However, in an example embodiment, at least two of the separate components shown in an exploded view in FIG. 3 will be cast or molded as a single, unitary component. Thus, although FIG. 3 shows all of the components separated from each other, it should be appreciated that in example embodiments, at least two of the components will not be separable. Moreover, in some cases, more than two (or even all) of the components may not be separable. Thus, FIG. 3 is merely exploded to more clearly show the portions of the bucket assembly 100 that may be combined together into a unitary component in various example embodiments.

As shown in FIGS. 2 and 3, the bucket assembly 100 may include an auger housing 110, an impeller housing 130 and a chute base 140. The auger housing 110 may further include sidewalls 120 and 120′. The auger housing 110 of some embodiments may be formed to extend radially spaced apart from the auger 32 to define an arc of coverage around a portion of the auger 32. As such, the auger housing 110 may extend along a substantial portion (or an entirety) of the longitudinal length of the auger 32 and further extend over at least of about 120 degrees and in some cases greater than 180 degrees radially around the auger 32 to contain and/or direct snow being moved responsive to operation of the snow removal device 10. The auger housing 110 may extend proximate to the surface over which the snow removal device 10 operates along a line parallel to the axis of rotation of the auger 32 and then form a continuous shield extending radially upwardly around a rear side of the auger 32. In an example embodiment, snow may be generally directed by the auger 32 toward the impeller 34, which may be disposed within the impeller housing 130 attached to a substantially centrally located portion of the auger housing 110. The sidewalls 120 and 120′ may be configured to lie substantially parallel to each other proximate to opposing respective longitudinal ends of the auger 132 to prevent snow from being expelled out of the sides of the bucket assembly 100.

Accordingly, snow may enter an open end of the bucket assembly 100, which may be oriented toward a front of the snow removal device 10 as shown in FIG. 1. Momentum may be imparted on the snow by the rotation of the auger 32 in a substantially rearward and/or inward direction pushing the snow inwardly (e.g., toward a longitudinal center of the auger 32) and rearward (e.g., toward the auger housing 110). The snow may move toward the impeller 34 where it may have further momentum imparted thereon and be directed into the chute base 140 via the impeller housing 130. The snow may then enter the chute body 52 and be ejected at the chute deflector 54.

In an example embodiment, as indicated above, at least two of the components of the bucket assembly 100 may be integrally formed together of a single and unitary molded or cast material. Thus, for example, the impeller housing 130 and the chute base 140 may be molded or cast as a single unitary piece without any discernable joint therebetween. Alternatively, the auger housing 110 and the impeller housing 130 may be molded or cast as a single unitary piece without any discernable joint therebetween. As yet another alternative, all three of the impeller housing 130, the chute base 140 and the auger housing 110 may be molded or cast as a single unitary piece without any discernable joint therebetween. In some embodiments, the sidewalls 120 and 120′ may be molded or cast as a single unitary piece in connection with the auger housing 110 without any discernable joint therebetween. The auger housing 110 having integrally formed sidewalls 120 and 120′ may be further integrally formed with the impeller housing 130 or the impeller housing 130 and the chute base 140 as described above.

In embodiments where the sidewalls 120 and 120′ are not integrally formed with the auger housing 110, where the chute base 140 is not integrally formed with the impeller housing 130, or where the auger housing 110 is not integrally formed with the impeller housing 130, these respective components may be joined together via bolts, rivets, dovetail joints, welds, snap fitting, or other joining methods. In some embodiments, the material used to form the components of the bucket assembly 100 may be a structural foam injection molded plastic. However, other resins, composite materials, plastics, or even metals may be used in other example embodiments. For example, steel, aluminum, or various other metals or alloys that are suitable for casting may be employed in some embodiments. In some embodiments, using a structural foam process may result in wall thicknesses for the components of the bucket assembly 100 of up to about 0.25 inches to substantially increase the strength of the plastic. Resins, composite materials or plastics may be injection molded, compression molded, or molded by any other suitable method. Any suitable casting technique may also be employed.

By employing processes described herein to integrally form the bucket assembly 100 such that at least two of the components thereof (i.e., two among the auger housing 110, the impeller housing 130 or the chute base 140) are molded or cast of the same material (e.g., at the same time) into a single and unitary assembly, the number of separate components that are required to be assembled and/or joined together during production of the snow removal device 10 may be reduced. The cost and complexity of assembly may therefore also be reduced. Furthermore, having eliminated joints between at least two of the components of the bucket assembly 100 via integrally forming those components simultaneously during the production process, in some cases the structural integrity and/or strength of the bucket assembly 100 may be improved by eliminating or reducing the potential for joint failures, joint weakness, and/or corrosion.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe exemplary embodiments in the context of certain exemplary combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. In cases where advantages, benefits or solutions to problems arc described herein, it should be appreciated that such advantages, benefits and/or solutions may be applicable to some example embodiments, but not necessarily all example embodiments. Thus, any advantages, benefits or solutions described herein should not be thought of as being critical, required or essential to all embodiments or to that which is claimed herein. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

1. A snow removal device comprising: a frame; an engine supported at least in part by the frame; a mobility assembly operably coupled to the frame and the engine to provide mobility of the snow removal device responsive at least in part to operation of the engine; and a bucket assembly operably coupled to the frame and housing a first stage material conveyor and an impeller, each of which operate via power from the engine to provide snow removal operations, the bucket assembly comprising one of each of a first stage housing, an impeller housing, and a discharge chute base, the bucket assembly being formed such that at least two among the first stage housing, the impeller housing, or the discharge chute base are integrally molded or cast as a single unitary component.
 2. The snow removal device of claim 1, wherein the first stage housing, the impeller housing, and the discharge chute base are each integrally formed together as the single unitary component.
 3. The snow removal device of claim 1, wherein the first stage housing and the impeller housing are integrally formed together as the single unitary component.
 4. The snow removal device of claim 1, wherein the impeller housing and the discharge chute base are integrally formed together as the single unitary component.
 5. The snow removal device of claim 1, wherein the first stage housing further comprises sidewalls, the sidewalls being integrally formed together with the first stage housing as a portion of the single unitary component.
 6. The snow removal device of claim 1, wherein the first stage housing further comprises sidewalls, the sidewalls being formed separately from the first stage housing and joined therewith to form the bucket assembly.
 7. The snow removal device of claim 1, wherein the single unitary component is formed of a plastic, composite, resin or metal material.
 8. The snow removal device of claim 1, wherein the single unitary component is formed by injection molding or compression molding.
 9. The snow removal device of claim 1, wherein the single unitary component is formed of structural foam injection molded plastic comprising a wall thickness of up to about 0.25 inches.
 10. A bucket assembly for a snow removal device, the bucket assembly comprising: a discharge chute base in communication with a discharge chute to direct snow ejected from the snow removal device; an impeller housing adjacent to the discharge chute; and a first stage housing adjacent to the impeller housing, the bucket assembly being formed such that at least two of the first stage housing, the impeller housing, or the discharge chute base are integrally molded or cast as a single unitary component.
 11. The bucket assembly of claim 10, wherein the first stage housing, the impeller housing, and the discharge chute base are each integrally formed together as the single unitary component.
 12. The bucket assembly of claim 10, wherein the first stage housing and the impeller housing are integrally formed together as the single unitary component.
 13. The bucket assembly of claim 10, wherein the impeller housing and the discharge chute base are integrally formed together as the single unitary component.
 14. The bucket assembly of claim 10, wherein the first stage housing further comprises sidewalls, the sidewalls being integrally formed together with the first stage housing as a portion of the single unitary component.
 15. The bucket assembly of claim 10, wherein the first stage housing further comprises sidewalls, the sidewalls being formed separately from the first stage housing and joined therewith to form the bucket assembly.
 16. The bucket assembly of claim 10, wherein the single unitary component is formed of a plastic, composite, resin or metal material.
 17. The bucket assembly of claim 10, wherein the single unitary component is formed by injection molding or compression molding.
 18. The bucket assembly of claim 10, wherein the single unitary component is formed of structural foam injection molded plastic comprising a wall thickness of up to about 0.25 inches. 